Method of repairing damage to fuselage barrel and associated apparatus and system

ABSTRACT

Disclosed herein is a method of repairing damage to a fuselage barrel, having a one-piece construction, of an aircraft. The method includes determining at least a first virtual splice line and a second virtual splice line along the fuselage barrel in a direction parallel to a longitudinal axis of the fuselage barrel. The method also includes detecting damage in a first section of the fuselage barrel between the first virtual splice line and the second virtual splice line. The method further includes cutting through the fuselage barrel along the first virtual splice line and the second virtual splice line to physically separate the first section from a main section of the fuselage barrel. The method also includes removing the first section from the main section of the fuselage barrel, and splicing a new section to the main section of the fuselage barrel in place of the first section.

FIELD

This disclosure relates generally to fuselage barrels of aircraft, andmore particularly to repairing fuselage barrels of aircraft made fromfiber-reinforced polymers.

BACKGROUND

With typical aircraft having fuselage barrels made from metal, thefuselage barrels include multiple, pre-existing, interconnectedsegments. Often, the interconnected segments of a conventional fuselagebarrel made from metal are coupled together at lap joints when theaircraft is initially assembled prior to first operation of theaircraft. When damage to such a conventional fuselage barrel occurs, thesegment or segments of the interconnected segments containing the damageare separated along production splices, removed from the fuselagebarrel, and replaced with an undamaged segment or segments. Becauseconventional fuselage barrels made from metal are initially manufacturedto have a multi-piece construction, repair of damage to a conventionalfuselage barrel made from metal can be accomplished with relative ease.

Technologically-advanced materials, such as fiber-reinforced polymers,allow for the construction of a one-piece fuselage barrel, whicheliminates the need to interconnect numerous panels around the fuselagebarrel. Conventional methods of removing and replacing fuselage panelsare inadequate for a fuselage barrel made of a once-piece construction.For example, conventional methods of repairing damage to a fuselagebarrel having a one-piece construction can be difficult, time-consuming,and expensive, and result in undesirable aesthetics.

SUMMARY

The subject matter of the present application has been developed inresponse to the present state of the art, and in particular, in responseto the problems and disadvantages associated with repairing damage tofuselage barrels having a one-piece construction, that have not yet beenfully solved by currently available techniques. Accordingly, the subjectmatter of the present application has been developed to provide a methodof repairing damage to a fuselage barrel having a one-piece constructionthat overcomes at least some of the above-discussed shortcomings ofprior art techniques. More specifically, in one implementation, in orderto utilize the structural and manufacturing efficiencies of a one-piecebarrel design, a method is disclosed that helps to ensure that airframesinvolved in a large scale damage event can be rapidly repaired andreturned to service.

Disclosed herein is a method of repairing damage to a fuselage barrel ofan aircraft. The fuselage barrel has a one-piece construction. Themethod includes, prior to damage of the fuselage barrel, determining atleast a first virtual splice line and a second virtual splice line alongthe fuselage barrel in a direction parallel to a longitudinal axis ofthe fuselage barrel. The method also includes detecting damage in afirst section of the fuselage barrel between the first virtual spliceline and the second virtual splice line. The method further includescutting through the fuselage barrel along the first virtual splice lineand the second virtual splice line to physically separate the firstsection from a main section of the fuselage barrel. The method alsoincludes removing the first section from the main section of thefuselage barrel. The method additionally includes splicing a new sectionto the main section of the fuselage barrel in place of the firstsection. The preceding subject matter of this paragraph characterizesexample 1 of the present disclosure.

The fuselage barrel extends longitudinally along the longitudinal axisfrom a first end to a second end. The first virtual splice line and thesecond virtual splice line both extend from the first end of thefuselage barrel to the second end of the fuselage barrel. The precedingsubject matter of this paragraph characterizes example 2 of the presentdisclosure, wherein example 2 also includes the subject matter accordingto example 1, above.

Splicing the new section to the main section of the fuselage barrelincludes forming a first butt joint, along the first virtual spliceline, and a second butt joint, along the second virtual splice line,parallel to the longitudinal axis, between the new section and the mainsection of the fuselage barrel. The preceding subject matter of thisparagraph characterizes example 3 of the present disclosure, whereinexample 3 also includes the subject matter according to any one ofexamples 1 or 2, above.

Splicing the new section to the main section of the fuselage barrelfurther includes overlaying the first butt joint with a first spliceplate, overlaying the second butt joint with a second splice plate, andfastening the first splice plate and the second splice plate to aninterior surface of the main section of the fuselage barrel and aninterior surface of the new section. The preceding subject matter ofthis paragraph characterizes example 4 of the present disclosure,wherein example 4 also includes the subject matter according to example3, above.

Removing the first section from the main section of the fuselage barrelincludes decoupling a frame element, extending circumferentially aboutthe fuselage barrel, from a first shear tie coupled to the fuselagebarrel over the first virtual splice line and from a second shear tiecoupled to the fuselage barrel over the second virtual splice line,decoupling the first shear tie from the fuselage barrel, and decouplingthe second shear tie from the fuselage barrel. Splicing the new sectionto the main section of the fuselage barrel includes coupling a firstreplacement shear tie to the first splice plate, wherein the firstreplacement shear tie is configured differently than the first sheartie, coupling a second replacement shear tie to the second splice plate,wherein the second replacement shear tie is configured differently thanthe second shear tie, and coupling the frame element to the firstreplacement shear tie and the second replacement shear tie. Thepreceding subject matter of this paragraph characterizes example 5 ofthe present disclosure, wherein example 5 also includes the subjectmatter according to example 4, above.

The first splice plate includes multiple first splice plate segmentsarranged substantially end-to-end along the first butt joint. The secondsplice plate includes multiple second splice plate segments arrangedsubstantially end-to-end along the second butt joint. Splicing the newsection to the main section of the fuselage barrel further includesintercoupling adjacent first splice plate segments with at least onecoupler fixed to and spanning at least portions of the adjacent firstsplice plate segments. Splicing the new section to the main section ofthe fuselage barrel further comprises intercoupling adjacent secondsplice plate segments with at least one coupler fixed to and spanning atleast portions of the adjacent second splice plate segments. Thepreceding subject matter of this paragraph characterizes example 6 ofthe present disclosure, wherein example 6 also includes the subjectmatter according to any one of examples 4 or 5, above.

A plurality of stringers, circumferentially spaced apart from each otherand extending along the fuselage barrel parallel to the longitudinalaxis of the fuselage barrel, are coupled to the fuselage barrel. Theplurality of stringers are grouped into at least a first pair ofstringers, including a first stringer, and a second pair of stringers,including a third stringer. The first virtual splice line extendsbetween the first pair of stringers. The second virtual splice lineextends between the second pair of stringers. The preceding subjectmatter of this paragraph characterizes example 7 of the presentdisclosure, wherein example 7 also includes the subject matter accordingto any one of examples 4-6, above.

Splicing the new section to the main section of the fuselage barrelincludes positioning a first filler between the first splice plate andthe first butt joint and between the first stringer and a secondstringer of the new section, and positioning a second filler between thesecond splice plate and the second butt joint and between the thirdstringer and a fourth stringer of the new section. The preceding subjectmatter of this paragraph characterizes example 8 of the presentdisclosure, wherein example 8 also includes the subject matter accordingto example 7, above.

The fuselage barrel, first splice plate, second splice plate, andplurality of stringers are made from a fiber-reinforced polymer. Thepreceding subject matter of this paragraph characterizes example 9 ofthe present disclosure, wherein example 9 also includes the subjectmatter according to any one of examples 7 or 8, above.

The aircraft includes multiple fuselage barrels coupled to each other inan end-to-end manner to form a fuselage of the aircraft. Removing thefirst section from the main section of the fuselage barrel includesdecoupling the first section of the fuselage barrel from adjacentfuselage barrels. Splicing the new section to the main section of thefuselage barrel includes coupling the new section to adjacent fuselagebarrels. The preceding subject matter of this paragraph characterizesexample 10 of the present disclosure, wherein example 10 also includesthe subject matter according to any one of examples 1-9, above.

The new section is pre-manufactured, prior to damage of the fuselagebarrel, responsive to a location on the fuselage barrel of the firstvirtual splice line and the second virtual splice line. The precedingsubject matter of this paragraph characterizes example 11 of the presentdisclosure, wherein example 11 also includes the subject matteraccording to any one of examples 1-10, above.

Determining at least the first virtual splice line and the secondvirtual splice line includes detecting a path along an interior surfaceof the fuselage barrel having a line of sight from one end of the pathto an opposite end of the path, and locating one of the first virtualsplice line and the second virtual splice line along the path. Thepreceding subject matter of this paragraph characterizes example 12 ofthe present disclosure, wherein example 12 also includes the subjectmatter according to any one of examples 1-11, above.

Each of the first section and the new section forms at least a quarterof the fuselage barrel. The preceding subject matter of this paragraphcharacterizes example 13 of the present disclosure, wherein example 13also includes the subject matter according to any one of examples 1-12,above.

The method further includes, prior to damage of the fuselage barrel,determining at least a third virtual splice line along the fuselagebarrel in a direction parallel to a longitudinal axis of the fuselagebarrel. The preceding subject matter of this paragraph characterizesexample 14 of the present disclosure, wherein example 14 also includesthe subject matter according to any one of examples 1-13, above.

Also disclosed is a fuselage barrel assembly of an aircraft. Thefuselage barrel assembly includes a main section of a fuselage barrelhaving a one-piece construction. The fuselage barrel assembly alsoincludes a new section of the fuselage barrel having a one-piececonstruction and spliced to the main section along a first butt jointbetween the main section and the new section and along a second buttjoint between the main section and the new section. The fuselage barrelassembly further includes a first splice plate fastened to the mainsection of the fuselage barrel and the new section over the first buttjoint, and a second splice plate fastened to the main section of thefuselage barrel and the new section over the second butt joint. Thefuselage barrel assembly additionally includes a first replacement sheartie coupled to the first splice plate, a second replacement shear tiecoupled to the second splice plate, and a frame element coupled to boththe first replacement shear tie and the second replacement shear tie.The preceding subject matter of this paragraph characterizes example 15of the present disclosure.

The main section includes a first stringer, extending parallel to thefirst butt joint, and a second stringer, extending parallel to thesecond butt joint. The new section includes a third stringer, extendingparallel to the first butt joint, and a fourth stringer, extendingparallel to the second butt joint. The fuselage barrel further includesa first filler between the first splice plate and the first butt jointand between the first stringer and the third stringer, and a secondfiller between the second splice plate and the second butt joint andbetween the second stringer and the fourth stringer. The precedingsubject matter of this paragraph characterizes example 16 of the presentdisclosure, wherein example 16 also includes the subject matteraccording to example 15, above.

The main section includes a first stringer, extending parallel to thefirst butt joint, and a second stringer, extending parallel to thesecond butt joint. The new section includes a third stringer, extendingparallel to the first butt joint, and a fourth stringer, extendingparallel to the second butt joint. The first splice plate is supportedon and fastened to the first stringer, the third stringer, and the firstfiller. The second splice plate is supported on and fastened to thesecond stringer, the fourth stringer, and the second filler. Thepreceding subject matter of this paragraph characterizes example 17 ofthe present disclosure, wherein example 17 also includes the subjectmatter according to example 16, above.

The first butt joint and the second butt joint are circumferentiallyspaced apart from each other. The first butt joint and the second buttjoint extend parallel to a longitudinal axis of the fuselage barrel. Thefirst butt joint and the second butt joint extend from a first end ofthe fuselage barrel to a second end of the fuselage barrel. Thepreceding subject matter of this paragraph characterizes example 18 ofthe present disclosure, wherein example 18 also includes the subjectmatter according to any one of examples 15-17, above.

The main section, new section, first splice plate, and second spliceplate is made from a fiber-reinforced polymer. The preceding subjectmatter of this paragraph characterizes example 19 of the presentdisclosure, wherein example 19 also includes the subject matteraccording to any one of examples 15-18, above.

An aircraft is disclosed. The aircraft includes a plurality of fuselagebarrel assemblies interconnected to each other. At least one of thefuselage barrel assemblies includes a main section of a fuselage barrelhaving a one-piece construction. At least the one of the fuselage barrelassemblies also includes a new section of the fuselage barrel having aone-piece construction and spliced to the main section along a firstbutt joint between the main section and the new section and along asecond butt joint between the main section and the new section. At leastthe one of the fuselage barrel assemblies additionally includes a firstsplice plate fastened to the main section of the fuselage barrel the newsection over the first butt joint, and a second splice plate fastened tothe main section of the fuselage barrel and the new section over thesecond butt joint. At least the one of the fuselage barrel assembliesfurther includes a first replacement shear tie coupled to the firstsplice plate, a second replacement shear tie coupled to the secondsplice plate, and a frame element coupled to both the first replacementshear tie and the second replacement shear tie. The plurality offuselage barrel assemblies are interconnected in an end-to-endconfiguration at abutting ends of respective fuselage barrels of thefuselage barrel assemblies. The preceding subject matter of thisparagraph characterizes example 20 of the present disclosure.

The described features, structures, advantages, and/or characteristicsof the subject matter of the present disclosure may be combined in anysuitable manner in one or more embodiments and/or implementations. Inthe following description, numerous specific details are provided toimpart a thorough understanding of embodiments of the subject matter ofthe present disclosure. One skilled in the relevant art will recognizethat the subject matter of the present disclosure may be practicedwithout one or more of the specific features, details, components,materials, and/or methods of a particular embodiment or implementation.In other instances, additional features and advantages may be recognizedin certain embodiments and/or implementations that may not be present inall embodiments or implementations. Further, in some instances,well-known structures, materials, or operations are not shown ordescribed in detail to avoid obscuring aspects of the subject matter ofthe present disclosure. The features and advantages of the subjectmatter of the present disclosure will become more fully apparent fromthe following description and appended claims, or may be learned by thepractice of the subject matter as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the subject matter may be more readilyunderstood, a more particular description of the subject matter brieflydescribed above will be rendered by reference to specific embodimentsthat are illustrated in the appended drawings. Understanding that thesedrawings depict only typical embodiments of the subject matter and arenot therefore to be considered to be limiting of its scope, the subjectmatter will be described and explained with additional specificity anddetail through the use of the drawings, in which:

FIG. 1 is a perspective view of an aircraft with multiple fuselagebarrel assemblies, according to one or more embodiments of the presentdisclosure;

FIG. 2 is a perspective view of a fuselage barrel assembly with virtualsplice lines, according to one or more embodiments of the presentdisclosure;

FIG. 3 is a perspective view of a first section of a fuselage barrelremoved from a main section of the fuselage barrel, according to one ormore embodiments of the present disclosure;

FIG. 4 is a perspective view of a new section of a fuselage barrel beingcoupled to a main section of the fuselage barrel, according to one ormore embodiments of the present disclosure;

FIG. 5 is a perspective view of a new section of a fuselage barrelcoupled to a main section of the fuselage barrel, according to one ormore embodiments of the present disclosure;

FIG. 6 is a perspective view of a new section of a fuselage barrelcoupled to a main section of the fuselage barrel, shown withoutfasteners, according to one or more embodiments of the presentdisclosure;

FIG. 7 is a perspective view of a new section of a fuselage barrelcoupled to a main section of the fuselage barrel, shown with fasteners,according to one or more embodiments of the present disclosure;

FIG. 8 is a side elevation view of a new section of a fuselage barrelcoupled to a main section of the fuselage barrel, shown without areplacement shear tie and frame element, according to one or moreembodiments of the present disclosure;

FIG. 9 is a side elevation view of a new section of a fuselage barrelcoupled to a main section of the fuselage barrel, shown with areplacement shear tie and frame element, according to one or moreembodiments of the present disclosure; and

FIG. 10 is a method of repairing damage to a fuselage barrel of anaircraft, according to one or more embodiments of the presentdisclosure.

DETAILED DESCRIPTION

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present disclosure.Appearances of the phrases “in one embodiment,” “in an embodiment,” andsimilar language throughout this specification may, but do notnecessarily, all refer to the same embodiment. Similarly, the use of theterm “implementation” means an implementation having a particularfeature, structure, or characteristic described in connection with oneor more embodiments of the present disclosure, however, absent anexpress correlation to indicate otherwise, an implementation may beassociated with one or more embodiments.

Referring to FIG. 1, one embodiment of an aircraft 100 is shown. Theaircraft 100 is a mobile complex structure. In some implementations, theaircraft 100 can be any of various other mobile complex structures, suchas a vehicle (e.g., watercraft, rocket, automobile, etc.) or astationary complex structure (e.g., a factory, building, machinery,etc.). The aircraft 100 includes a fuselage 105, a pair of wings 160coupled to and extending from the fuselage 105, a vertical stabilizer162 coupled to and extending from the fuselage 105, and a pair ofhorizontal stabilizers 164 coupled to and extending from the fuselage105 or the vertical stabilizer 162. The aircraft 100 includes featuresrepresentative of a commercial passenger or military transport aircraft.However, the aircraft 100 can be any of various other types ofcommercial or non-commercial aircraft, such as personal aircraft,fighter jets, helicopters, spacecraft, and the like.

The fuselage 105 of the aircraft 100 includes a plurality of fuselagebarrel assemblies 101 interconnected to each other to form the fuselage105. As shown in FIG. 2, each fuselage barrel assembly 101 includes afuselage barrel 102. The fuselage barrel 102 has a hollow and elongatetubular construction. For example, the fuselage barrel 102 extendslengthwise along a longitudinal axis 106, which defines a central axisof the fuselage barrel 102, from a first end 112 of the fuselage barrel102 to a second end 114 of the fuselage barrel 102. The cross-sectionalshape of the fuselage barrel 102 along a plane perpendicular to thelongitudinal axis 106 is generally a circular or an annular ring.

The fuselage barrel 102 is formed as one-piece, monolithic,construction. In other words, the fuselage barrel 102 is seamless anddoes not include components that are separately formed and thenassembled or joined together. Rather, the entire fuselage barrel 102 isformed as one-piece during the same manufacturing process. In someimplementations, the fuselage barrel 102 is made from a fiber-reinforcedpolymer (e.g., carbon-fiber-reinforced polymer). For example, thefuselage barrel 102 can be formed from a continuous length of fiber thatis spun, along with uncured resin or epoxy, into the shape of thefuselage barrel 102 and cured. After the fuselage barrel 102 is cured,features, such as window openings 166 and doorways 168, can be formedinto the fuselage barrel 102 by cutting and removing correspondingportions of the cured fuselage barrel 102.

The fuselage 105 of the aircraft 100 is formed by interconnecting theplurality of fuselage barrel assemblies 101 in an end-to-end manner.Moreover, the fuselage barrel assemblies 101 are removablyinterconnected to each other by interconnecting respective first ends112 and second ends 114 of adjacent fuselage barrels 102. Generally, thefirst end 112 and second end 114 of adjacent fuselage barrels 102together form a production splice (e.g., seam) of the fuselage 105, suchthat the fuselage 105 includes multiple production splices. The firstend 112 and second end 114 of adjacent fuselage barrels 102 can beremovably interconnected using any of various coupling techniques, suchas lap joints or butt joints that are reinforced with splicing elements.In some implementations, the first end 112 and second end 114 ofadjacent fuselage barrels 102 can be removably interconnected using abulkhead or similar interconnecting element. The first end 112 andsecond end 114 can be removably interconnected by using fasteners thatare tightenable to interconnect together the first end 112 and secondend 114 and loosenable to disconnect the first end 112 and second end114 from each other.

Referring still to FIG. 2, each fuselage barrel assembly 101 includes aplurality of stringers 116 that are circumferentially spaced apart fromeach other about an interior surface 122 of the fuselage barrel 102.Moreover, the plurality of stringers 116 extend along the interiorsurface 122 of the fuselage barrel 102 in a direction parallel to thelongitudinal axis 106 of the fuselage barrel 102. The stringers 116 canextend an entire length of the fuselage barrel 102 from the first end112 to the second end 114. The stringers 116 are coupled to the interiorsurface 122 of the fuselage barrel 102 and promote structural rigidityof the fuselage barrel 102. As shown in FIG. 9, each stringer 116includes a hat portion 180 (e.g., raised portion) and flanges 182extending from opposite sides of the hat portion 180. The flanges 182are coupled directly to the interior surface 122 of the fuselage barrel102. In some implementations, the stringers 116 are made from afiber-reinforced polymer and co-cured with the fuselage barrel 102 tocouple the flanges 182 to the interior surface 122 of the fuselagebarrel 102.

Each fuselage barrel assembly 101 further includes a plurality of shearties, such as first shear tie 134 and second shear tie 136, removablycoupled to the interior surface 122 of the fuselage barrel 102.Referring to FIG. 9, each shear tie includes an upright portion 184 andflanges 186 extending perpendicularly relative to the upright portion184. The flanges 186 of each shear tie are substantially parallel to theinterior surface 122 of the fuselage barrel 102 and the upright portion184 of each shear tie is perpendicular to the interior surface 122 ofthe fuselage barrel 102. In one implementation, each shear tie isremovably coupled to the interior surface 122 of the fuselage barrel102, between a respective pair of stringers 116, via one or morefasteners 176 that extend through the flanges 186 and at least partiallyinto the fuselage barrel 102. As shown in FIG. 9, the shear ties can beconfigured such that they extend from stringer to stringer of arespective pair of stringers 116. In such an implementation, each sheartie may rest on the flanges 182 of the pair of stringers 116 and one ormore fasteners 176 may extend through the flanges 186 of the shear tieand flanges 182 of the pair of stringers 116 and at least partially intothe fuselage barrel 102 to removably couple the shear tie to theinterior surface 122 of the fuselage barrel 102. Although two rows offasteners 176 are shown on each side of the splice line, defined by theedges 170, more or less than two rows of fasteners 176 (e.g., three rowsof fasteners 176) may be used on each side of the splice line.

Additionally, each fuselage barrel 102 includes a plurality of frameelements 132 each removably coupled, such as via fasteners 176, to theupright portions 184 of shear ties that are circumferentially alignedalong a circumference of the fuselage barrel 102. When removably coupledto the shear ties, the frame elements 132 promote structural rigidity ofthe fuselage barrel 102 by preventing ballooning of the fuselage barrel102. Each frame element 132 is an at least partially annular plate witha curvature complementing the curvature of the interior surface 122 ofthe fuselage barrel 102. In some implementations, at least one of theframe elements 132 extends along at least a quarter of the circumferenceof the interior surface 122 of the fuselage barrel 102. In certainimplementations, multiple frame elements 132 can be circumferentiallyaligned to effectively or cooperatively extend along an entirety or amajority of the circumference of the interior surface 122 of thefuselage barrel 102. According to one implementation, at least one ofthe frame elements 132 extends along an entirety of the circumference ofthe interior surface 122 of the fuselage barrel 102. The frame element132 includes a plurality of tabs 139 and notches 141 between the tabs139. The tabs 139 receive the fasteners 176 that couple the frameelement 132 to the shear ties. In contrast, the notches 141 defines aspace into which the hat portion 180 of a stringer 116 may extend. Inthis manner, the frame elements 132 are indirectly coupled to thefuselage barrel 102 via the shear ties.

After each of the fuselage barrel assemblies 101 are assembled andcoupled together to form the fuselage 105 of the aircraft 100, thefurther assembly, testing, and/or manufacturing process can be performedto ready the aircraft 100 for operation. Prior to operation of theaircraft 100, virtual splice lines along the fuselage barrel 102, in adirection parallel to the longitudinal axis 106 of the fuselage barrel102, are determined. Referring to FIG. 2, representations of fourvirtual splice lines (e.g., first virtual splice line 104A, secondvirtual splice line 104B, third virtual splice line 104C, and fourthvirtual splice line 104D) are shown. Although four virtual splice linesare shown, more than four virtual splice lines can be determined priorto operation of the aircraft 100. As defined herein, a virtual spliceline can be considered a pre-defined splice or a splice that is modeledin virtual space as a provision for a possible future repair.

The circumferential location and quantity of the virtual splice lines onthe fuselage barrel 102 can be determined as the aircraft 100 isdesigned and before assembly of the aircraft 100, during assembly of theaircraft 100, or after the aircraft 100 is assembled. Determination ofthe quantity and circumferential location of the virtual splice linescan be dependent on a variety of factors.

The location and quantity of the virtual splice lines can be based onthe ease of cutting through the fuselage barrel 102 without obstructionfrom other features of or objects coupled to the fuselage barrel 102.For example, in one implementation, at least one of the virtual splicelines is located along a path along the interior surface 122 of thefuselage barrel 102 that has a line of sight from one end of the path(e.g., the first end 112 of the fuselage barrel 102) to an opposite endof the path (e.g., the second end 114 of the fuselage barrel 102). Inanother example, at least one of the virtual splice lines is locatedalong a path along the interior surface 122 of the fuselage barrel 102that passes through the fewest features of the fuselage barrel 102 orobjects coupled to the fuselage barrel 102. According to oneimplementation, at least one of the virtual splice lines extendsparallel to and between a pair of stringers (e.g., pair of stringers 118and pair of stringers 119), of the plurality of stringers 116, to limitthe number of obstructions through which the virtual splice line passesthrough. Although at least a portion of each virtual splice line extendsparallel to the longitudinal axis 106, in some implementations, aportion of at least one virtual splice line may extend diagonally orperpendicularly relative to the longitudinal axis 106 (e.g.,circumferentially) to avoid objects or where damage 107 to the aircraft100 is minimal.

In some implementations, the location and quantity of the virtual splicelines can be based on a desired size and/or quantity of new sections 110that are pre-manufactured or available prior to damage of the fuselagebarrel 102 of the aircraft 100. As defined herein, a new section 110 canbe pre-manufactured by using a process that is qualified to beequivalent to the process for manufacturing the fuselage barrel 102 orexcising the new section 110 from another (e.g., spare) fuselage barrel102. For example, where new sections 110 include only quarter sectionsof the fuselage barrel 102, there may be four virtual splice lines anequidistance apart from each other to divide the fuselage barrel 102into four equally sized sections. As shown in FIG. 2, the fuselagebarrel 102 includes four virtual splice lines (e.g., first virtualsplice line 104A, second virtual splice line 104B, third virtual spliceline 104C, and fourth virtual splice line 104D) that divide up thefuselage barrel 102 into four sections (e.g., first section 108A, secondsection 108B, third section 108C, and fourth section 108D).

In certain implementations, the location and quantity of the virtualsplice lines are determined automatically by a computing apparatus. Thecomputing apparatus can receive inputs regarding the designedconfiguration of the fuselage barrel assembly 101, as well as any ofvarious user-specified inputs, such as a desired one of theabove-mentioned or other approaches for determining the virtual splicelines. Then, based on the inputs, the computing apparatus determines thelocation and quantity of the virtual splice lines before damage 107 tothe fuselage barrel 102 in operation or before/during assembly of thefuselage barrel 102 and fuselage barrel assembly 101. The computingapparatus can be any of various computing devices known in the art.

After the virtual splice lines are determined, the aircraft 100 can beoperated as desired. Should damage 107 occur to the fuselage barrel 102of a fuselage barrel assembly 101 during operation, the section of thefuselage barrel 102 in which the damage 107 occurs is determined afterthe damage 107 is detected. In some implementations, the section of thefuselage barrel 102 in which the entirety of the damage 107 occurs isdetermined. In some implementations, if damage 107 extends across avirtual splice line into two sections of the fuselage barrel 102, otherpredetermined, alternative, splice lines can be used to determine analternative section of the fuselage barrel 102 in which the entirety ofthe damage 107 occurs.

After the section of the fuselage barrel 102 with the damage 107 isdetermined, the fuselage barrel 102 is cut along the virtual splicelines, defining the section of the fuselage barrel 102, to physicallyseparate the section of the fuselage barrel 102 from a main or remainingsection of the fuselage barrel 102. For example, as shown in FIG. 3, thefirst section 108A, which includes the entirety of the damage 107, isseparated from the main section 103 of the fuselage barrel 102 bycutting along the first virtual splice line 104A and the second virtualsplice line 104B. Also, in some embodiments, the first section 108Awould be disconnected from adjacent fuselage assemblies 101 while themain section 103 remains connected to adjacent fuselage assemblies 101.Generally, the entire first section 108A is removed even if the damage107 occupies only a small percentage of the first section 108A. Asdefined herein, the main section 103 of the fuselage barrel 102 is thesection of the fuselage barrel 102 that remains after the section of thefuselage barrel 102 with the damage 107 is removed.

Before the section of the fuselage barrel 102 with the damage 107 isremoved from the main section of the fuselage barrel, and before orafter the fuselage barrel 102 is cut along the splice lines, thefuselage barrel assembly 101 is at least partially disassembled inpreparation for removing the section with the damage 107. For example,referring again to FIG. 3, the frame elements 132 and the respectiveshear ties 134, 136 spanning the first and second virtual splice lines104A, 104B are removed from the fuselage barrel 102 before the firstsection 108A is removed from the main section 103. Removal of the frameelements 132 and shear ties 134, 136 can be accomplished by looseningand removing the fasteners 176 coupling together the shear ties 134, 136and the fuselage barrel 102 and, in some implementations, the fasteners176 coupling together the frame elements 132 and the shear ties 134,136. However, in some implementations, the shear ties 134, 136 areformed integrally (e.g., co-cured) with the frame elements 132, suchthat removal of the shear ties 134, 136 from the frame elements 132includes trimming, shearing, or cutting the shear ties 134, 136 from theframe elements 132. Also, in certain implementations, such as where theshear ties 134, 136 are non-removably coupled to the fuselage barrel 102(e.g., being flush against and adhered or bonded to the interior surface122 of the fuselage barrel 102), removal of the shear ties 134, 136 fromthe fuselage barrel 102 may include trimming, shearing, or cutting theshear ties 134, 136 from the fuselage barrel 102. It is noted that inFIG. 3 only one of the multiple frame elements 132 and only some of theshear ties 134, 136 are shown being removed from the fuselage barrel 102for clarity in showing other features of the fuselage barrel assembly101.

As shown in FIG. 4, after the first section 108A of the fuselage barrel102 is removed from the main section 103 of the fuselage barrel 102, anew section 110 is spliced to the main section 103 in place of the firstsection 108A to create a repaired fuselage barrel assembly 101A. The newsection 110 is configured the same as the first section 108A. Forexample, the new section 110 has the same size and shape as the firstsection 108A. Additionally, the new section 110 is made from the samematerial as the first section 108A, which, in some implementations, is afiber-reinforced polymer. Moreover, in certain implementations, the newsection 110 is made before the damage 107 occurs to the first section108A. In other words, the new section 110 is made to match the firstsection 108A after the first and second virtual splice lines 104A, 104Bare determined, but before any damage occurs to the first section 108A.However, in other implementations, the new section 110 is made to matchthe first section 108A after the first and second virtual splice lines104A, 104B are determined and after the damage 107 occurs to the firstsection 108A.

The new section 110 is spliced to the main section 103 by constructing,between the new section 110 and the main section 103, a first butt joint124 along the first virtual splice line 104A and a second butt joint 125along the second virtual splice line 104B. At least a portion of, or anentirety of, in some implementations, the first butt joint 124 and thesecond butt joint 125 extends parallel to the longitudinal axis 106. Asshown in FIGS. 8 and 9 any one of the first butt joint 124 and thesecond butt joint 125 is formed by locating the new section 110 relativeto the main section 103 such that edges 170 of the new section 110 andthe main section 103, between the first and second ends 112, 114 of thefuselage barrel 102, substantially abut, or are directly adjacent, eachother. In other words, no portion of the new section 110 and the mainsection 103 overlap with each other at the first butt joint 124 and thesecond butt joint 125.

Referring to FIGS. 4-7, the first butt joint 124 and the second buttjoint 125 are reinforced by coupling together the new section 110 andthe main section 103 with respective first and second splice plates 126,127 that overlay the first butt joint 124 and the second butt joint 125,respectively. Referring again to FIGS. 8 and 9, a portion of the firstand second splice plates 126, 127 is fixed to the new section 110 andanother portion of the first and second splice plates 126, 127 is fixedto the main section 103. Accordingly, the first splice plate 126, whenfixed to the new section 110 and the main section 103, spans across thefirst butt joint 124 and the second splice plate 127, when fixed to thenew section 110 and the main section 103, spans across the second buttjoint 125. In some implementations, the first and second splice plates126, 127 sit flush against the interior surfaces 122, 128 of the mainsection 103 and the new section 110, interposed between the first andsecond stringers 150, 152 and the third and fourth stringers 154, 156,respectively, such that the first and second splice plates 126, 127contact and are directly coupled to the interior surfaces 122, 128.However, in alternative implementations, such as shown in FIGS. 8 and 9,the first and second splice plates 126, 127 sit flush against theflanges 182 of the first and second stringers 150, 152 and the third andfourth stringers 154, 156, respectively, such that a gap exists betweenthe interior surfaces 122, 128 of the main section 103 and the newsection 110. The gap can be filled with a filler, such as a respectiveone of first and second fillers 146, 148. Each of the first and secondfillers 146, 148 can be made from any of various materials, such as, forexample, a fiber-reinforced polymer, polymer, metal, and/or the like.Alternatively, in certain implementations, each shear tie may restdirectly on the interior surfaces 122, 128 of the fuselage barrel 102,without a filler.

The first and second splice plates 126, 127 can be fixed to the mainsection 103 and new section 110 using fasteners, such as the samefasteners 176, or similar fasteners, used to fix the first and secondshear ties 134, 136 to the fuselage barrel 102. The fasteners 176 extendthrough the first and second splice plates 126, 127, through the flanges182 of the stringers and/or fillers in some implementations, and intoone of the main section 103 and new section 110. When fixed to the mainsection 103 and new section 110 over the first and second butt joints124, 125, the respective first and second splice plates 126, 127facilitate the transfer of pressure loads across the first and secondbutt joints 124, 125 and help to promote load continuity in the fuselagebarrel 102 in the circumferential or a hoopwise direction.

The first and second splice plates 126, 127 each has a width greaterthan a thickness, and a length greater than the width. Moreover, thefirst and second splice plates 126, 127 are made from the same materialas the main section 103 and new section 110 of the fuselage barrel 102.For example, the first and second splice plates 126, 127 can be madefrom a fiber-reinforced polymer. The matrix of the fiber-reinforcedpolymer of the first and second splice plates 126, 127 is cured prior tofixing the first and second splice plates to the main section 103 andnew section 110.

In some implementations, each of the first and second splice plates 126,127 is a continuous, one-piece and non-segmented, plate that extendsfrom a first end of the respective first and second butt joints 124, 125(e.g., at the first end 112 of the fuselage barrel 102) to a second endof the respective first and second butt joints 124, 125 (e.g., at thesecond end 114 of the fuselage barrel 102). However, as shown in FIG. 5,each of the first and second splice plates 126, 127 can be segmentedinto multiple, interconnected, first and second splice plate segments142, 144, respectively. Generally, the first splice plate segments 142overlay the first butt joint 124 in an end-to-end manner longitudinallyalong the first butt joint 124, and the second splice plate segments 144overlay the second butt joint 126 in an end-to-end manner longitudinallyalong the second butt joint 126. Segmenting the first and second spliceplates 126, 127 into multiple first and second splice plate segments142, 144 promotes tolerance to damage of the first and second spliceplates 126, 127 by ensuring that damage to one splice plate segment doesnot impact the performance of the other splice plate segments and thusthe performance of the splice plate as a whole. To facilitate loadcontinuity in the fuselage barrel 102 in a fore-aft or longitudinaldirection, one or more couplers 130 fixed to and spanning at leastportions of adjacent splice plate segments forming the splice plates. Inother words, the coupler 130 effectively splices together the spliceplate segments of a given splice plate. The coupler 130 can be any ofvarious couplers, such as plates, brackets, shear ties, and the like.Moreover, the coupler 130 can be fixed to the splice plate segments viaany of various techniques, such as fasteners, bonding, and the like.

Referring to FIG. 9, splicing the new section 110 to the main section103 also includes fixing replacement shear ties, such as first andsecond replacement shear ties 138, 140, to the first and second spliceplates 126, 127, respectively. The replacement shear ties 138, 140 canbe fixed to the first and second splice plates 126, 127 by fasteners,such as fasteners 176, that extend through flanges 186 of eachreplacement shear tie 138, 140. Like the first and second shear ties134, 136, the replacement shear ties 138, 140 includes flanges 186 andan upright 184 extending transversely from the flanges 186. However,because the replacement shear ties 138, 140 are fixed to the first andsecond splice plates 126, 127, and the shear ties 134, 136 are fixed tothe flanges of the stringers or the interior surface of the fuselagebarrel 102, the replacement shear ties 138, 140 are located moreradially inwardly than the shear ties 134, 136. Accordingly, to ensurethe radial location of the frame elements 132 remains unchanged, thereplacement shear ties 138, 140 are configured differently than theshear ties 134, 136. More specifically, in some implementations,apertures, for receiving fasteners 176 to fix a frame element 132, inthe upright portion 184 of each replacement shear tie 138, 140 arelocated closer to the flanges 186 than the shear ties 134, 136.Additionally, according to certain implementations, the size of theupright portion 184 of the replacement shear ties 138, 140, may bedifferent (e.g., shorter) than the upright portion 184 of the shear ties134, 136. The shear ties 134, 136 (e.g., production shear ties) and thereplacement shear ties 138, 140 can be made from a fiber-reinforcedpolymer that is the same as or similar to that of the fuselage barrel102.

With the replacement shear ties 138, 140 fixed to the first and secondsplice plates 126, 127, respectively, a frame element 132 can be fixedto the upright portion 184 of each of the replacement shear ties 138,140. Additionally, each frame element 132 is reattached to the originalshear ties 134, 136 secured to the main section 103 of the fuselagebarrel 102 and circumferentially aligned with the replacement shear ties138. Furthermore, although not shown, shear ties 134, 136 are fixed tothe new section 110, either before or after the new section 110 formsthe first and second butt joints 124, 125 with the main section 103.Each frame element 132 is attached to the shear ties 134, 136 fixed tothe new section 110 of the fuselage barrel 102 and circumferentiallyaligned with the replacement shear ties 138. In some implementations,the frame elements 132 are fixed to the upright portions 184 via one ormore fasteners 176. In some implementations, the frame elements 132 arefixed to the replacement shear ties 138, 140 before the replacementshear ties 138, 140 are fixed to the first and second splice plates 126,127.

As shown in FIGS. 6 and 7, the new section 110 of the repaired fuselageassembly 101A is reconnected to one or more original or productionfuselage assemblies 101 (e.g., the same one or more fuselage assemblies101 from which the first section 108A was disconnected to perform therepair to the fuselage barrel 102 of the damaged fuselage assembly).Generally, in some embodiments, a hoop strap 190 is used to splicetogether the ends (e.g., end 112) of fuselage barrels 102 of adjacentfuselage barrel assemblies 101. The hoop strap 190 extends about aninterior of the adjacent fuselage barrel assemblies in a circumferentialdirection that is perpendicular to the longitudinal axis 106. Moreover,the hoop strap 190 spans over the joint between abutting ends ofadjacent fuselage barrels in an axial or longitudinal directionperpendicular to the circumferential direction. The hoop strap 190 canbe fixed to the adjacent fuselage barrels using any of various fixationelements, such as fasteners 176. In some implementations, the hoop strap190 includes multiple hoop strap segments arranged in an end-to-endconfiguration along the joint between abutting ends of adjacent fuselagebarrels.

The joint between abutting ends of adjacent fuselage barrels may furtherinclude at least one longitudinal member 194 that longitudinally spansover the abutting ends and the hoop strap 190. In some implementations,the longitudinal member 194 can includes two longitudinal portions thatextend an angle relative to each other such that the longitudinal member194 has a substantially L-shaped or V-shaped cross-section. Thelongitudinal member 194 can be affixed to the flange of a respective oneof the stringers 116 on each of the fuselage barrels abutting each otherand to the hoop strap 190 using any of various fixation elements, suchas fasteners 176. If necessary, footings (not shown) can be positionedbetween each longitudinal member 194 and the flanges of the stringers116 to promote proper spacing between the longitudinal member 194 andthe flanges of the stringers 116. In some implementations, as shown, twolongitudinal members 194 are positioned, in a spaced apart manner fromeach other, and fixed between each pair of stringers 116. Because thelongitudinal members 194 between a pair of stringers 116 arecircumferentially spaced apart, such longitudinal members 194 are usedwith a pair of stringers 116 between which no longitudinalpost-production splice line or cut (e.g., edges 170) in the fuselagebarrel 102 is present.

For a pair of stringers 116 between which a longitudinal post-productionsplice line or cut in the fuselage barrel 102 is present, such as withthe repaired fuselage assembly 101A, the joint includes an additionalfitting or splice plate over the hoop strap 190 between the spaced apartlongitudinal members 194. The additional fitting between thelongitudinal members 194 spans and is affixed to the hoop strap 190,such as with fasteners 176, which helps to distribute circumferentialloads placed on the joint. In some implementations, the two longitudinalmembers 194 and the additional fitting between the longitudinal members194 can be consolidated into a single fitting, such as the H-fitting192. The H-fitting 192 includes two longitudinally straight portions 196similar to two longitudinal members 194. The two longitudinally straightportions 196 are circumferentially connected by a lateral portion 198 orcross-member, which spans the joint and the hoop strap 190 and helps todistribute circumferential loads between the two longitudinally straightportions 196. Accordingly, in plan view, the H-fitting 192 has asubstantially H-shape. The two longitudinally straight portions 196 areaffixed to one of the splice plates 126, 127 on one side of theH-fitting 192 and to the flanges (or footings) of the stringers 116 onthe adjacent production fuselage assembly on the opposite side of theH-fitting 192, such as with fasteners 176. The lateral portion 198 ofthe H-fitting 192 can be affixed to the hoop strap 190, such as withfasteners 176. Because of the added thickness of the splice plate, insome implementations, a footing between longitudinal members 194 or astraight portion 196 of the H-fitting 192 and the flange of the stringeron the repaired fuselage assembly 101A, to which the longitudinalmembers 194 of H-fitting 192 is affixed, is not needed.

Referring to FIG. 10, one embodiment of a method 200 of repairing damageto a fuselage barrel of an aircraft is shown. The fuselage barrel canhave a one-piece construction and be made from a fiber-reinforcedpolymer in certain implementations. Moreover, the features and elementsassociated with the method 200 can be the same as or analogous to thelike features and elements of the aircraft 100 and fuselage barrelassembly 101 presented above.

The method 200 includes, prior to damage of the fuselage barrel,determining at least a first virtual splice line and a second virtualsplice line along the fuselage barrel in a direction parallel to alongitudinal axis of the fuselage barrel at step 202. In someimplementations, determining the first virtual splice line and/or thesecond virtual splice line includes detecting a path or paths along aninterior surface of the fuselage barrel that has a line of sight fromone end of the path or paths to an opposite end of the path. The firstvirtual splice line and/or the second virtual splice line is locatedalong the one of the paths. The method 200 may also include determiningat least a third virtual splice line along the fuselage barrel 102 in adirection parallel to a longitudinal axis 106 of the fuselage barrel102, prior to damage of the fuselage barrel 102.

Additionally, the method 200 includes detecting damage in a firstsection of the fuselage barrel between the first virtual splice line andthe second virtual splice line at step 204. Generally, the damage to thefuselage barrel can be detected manually, such as via a visualinspection, or automatically, such as via sensors and electronicsystems.

The method 200 also includes cutting through the fuselage barrel alongthe first virtual splice line and the second virtual splice line tophysically separate the first section from a main section of thefuselage barrel at step 206. Cutting the fuselage barrel can beperformed using any of various cutting techniques known in the art, suchas mechanical (e.g., blade) cutting, optical or laser cutting, plasmacutting, and the like. Generally, cutting the fuselage barrel does notinclude cutting the underlying sub-structure attached to the fuselagebarrel, such as shear ties and frame elements. In some implementations,the shear ties and frame elements are removed prior to cutting throughthe fuselage barrel.

Also, the method 200 includes removing the first section from the mainsection of the fuselage barrel at step 208. Removing the first sectionfrom the main section can include decoupling a frame element from afirst shear tie coupled to the fuselage barrel over the first virtualsplice line and from a second shear tie coupled to the fuselage barrelover the second virtual splice line. Additionally, removing the firstsection from the main section may include decoupling the first shear tiefrom the fuselage barrel and decoupling the second shear tie from thefuselage barrel. As defined herein, decoupling can include trimming,cutting, shearing, loosening, unfastening, or otherwise removed. Wherethe aircraft includes multiple fuselage barrels, removing the firstsection from the main section of the fuselage barrel can includedecoupling, along production splices, the first section of the fuselagebarrel from adjacent fuselage barrels.

The method 200 additionally includes splicing a new section to the mainsection of the fuselage barrel in place of the first section at step210. Splicing the new section to the main section of the fuselage barrelcan include forming a first butt joint, along the first virtual spliceline, and a second butt joint, along the second virtual splice line.Splicing can include overlaying the first butt joint with a first spliceplate, overlaying the second butt joint with a second splice plate, andfastening the first splice plate and the second splice plate to the mainsection of the fuselage barrel the new section. Splicing may alsoinclude coupling a first replacement shear tie to the first spliceplate, coupling a second replacement shear tie to the second spliceplate, and coupling the frame element to the first replacement shear tieand the second replacement shear tie. Furthermore, splicing can includeintercoupling adjacent first splice plate segments of the first spliceplate with at least one coupler, and intercoupling adjacent secondsplice plate segments of the second splice plate with at least onecoupler. Splicing can also include positioning a first filler betweenthe first splice plate and the first butt joint and between the firststringer and a third stringer of the new section and positioning asecond filler between the second splice plate and the second butt jointand between the second stringer and a fourth stringer of the newsection.

In the above description, certain terms may be used such as “up,”“down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,”“over,” “under” and the like. These terms are used, where applicable, toprovide some clarity of description when dealing with relativerelationships. But, these terms are not intended to imply absoluterelationships, positions, and/or orientations. For example, with respectto an object, an “upper” surface can become a “lower” surface simply byturning the object over. Nevertheless, it is still the same object.Further, the terms “including,” “comprising,” “having,” and variationsthereof mean “including but not limited to” unless expressly specifiedotherwise. An enumerated listing of items does not imply that any or allof the items are mutually exclusive and/or mutually inclusive, unlessexpressly specified otherwise. The terms “a,” “an,” and “the” also referto “one or more” unless expressly specified otherwise. Further, the term“plurality” can be defined as “at least two.”

Additionally, instances in this specification where one element is“coupled” to another element can include direct and indirect coupling.Direct coupling can be defined as one element coupled to and in somecontact with another element. Indirect coupling can be defined ascoupling between two elements not in direct contact with each other, buthaving one or more additional elements between the coupled elements.Further, as used herein, securing one element to another element caninclude direct securing and indirect securing. Additionally, as usedherein, “adjacent” does not necessarily denote contact. For example, oneelement can be adjacent another element without being in contact withthat element.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of the items in the list may be needed. Theitem may be a particular object, thing, or category. In other words, “atleast one of” means any combination of items or number of items may beused from the list, but not all of the items in the list may berequired. For example, “at least one of item A, item B, and item C” maymean item A; item A and item B; item B; item A, item B, and item C; oritem B and item C. In some cases, “at least one of item A, item B, anditem C” may mean, for example, without limitation, two of item A, one ofitem B, and ten of item C; four of item B and seven of item C; or someother suitable combination.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

The schematic flow chart diagrams included herein are generally setforth as logical flow chart diagrams. As such, the depicted order andlabeled steps are indicative of one embodiment of the presented method.Other steps and methods may be conceived that are equivalent infunction, logic, or effect to one or more steps, or portions thereof, ofthe illustrated method. Additionally, the format and symbols employedare provided to explain the logical steps of the method and areunderstood not to limit the scope of the method. Although various arrowtypes and line types may be employed in the flow chart diagrams, theyare understood not to limit the scope of the corresponding method.Indeed, some arrows or other connectors may be used to indicate only thelogical flow of the method. For instance, an arrow may indicate awaiting or monitoring period of unspecified duration between enumeratedsteps of the depicted method. Additionally, the order in which aparticular method occurs may or may not strictly adhere to the order ofthe corresponding steps shown.

The present subject matter may be embodied in other specific formswithout departing from its spirit or essential characteristics. Thedescribed embodiments are to be considered in all respects only asillustrative and not restrictive. All changes which come within themeaning and range of equivalency of the claims are to be embraced withintheir scope.

What is claimed is:
 1. A fuselage barrel assembly of an aircraft,comprising: a main section of a fuselage barrel having a one-piececonstruction; a new section of the fuselage barrel having a one-piececonstruction and spliced to the main section along a first butt jointbetween the main section and the new section and along a second buttjoint between the main section and the new section, wherein: the firstbutt joint and the second butt joint extend parallel to a longitudinalaxis of the fuselage barrel; and the main section and the new section ofthe fuselage barrel each define less than a full circumference of thefuselage barrel; a first splice plate fastened to the main section ofthe fuselage barrel and the new section over the first butt joint; asecond splice plate fastened to the main section of the fuselage barreland the new section over the second butt joint; a first replacementshear tie coupled to the first splice plate; a second replacement sheartie coupled to the second splice plate; and a frame element coupled toboth the first replacement shear tie and the second replacement sheartie; wherein: the main section comprises a first stringer, extendingparallel to the first butt joint and a second stringer, extendingparallel to the second butt joint; the new section comprises a thirdstringer, extending parallel to the first butt joint, and a fourthstringer, extending parallel to the second butt joint; the firststringer comprises a first flange; the second stringer comprises asecond flange; the third stringer comprises a third flange; the fourthstringer comprises a fourth flange; the first splice plate is attachedto the first flange of the first stringer and the third flange of thethird stringer; the second splice plate is attached to the second flangeof the second stringer and the fourth flange of the fourth stringer; thefirst replacement shear tie is attached to the first flange of the firststringer and the third flange of the third stringer such that the firstsplice plate and the first flange are interposed between the firstreplacement shear tie and the main section of the fuselage barrel andthe first splice plate and the third flange are interposed between thefirst replacement shear tie and the new section of the fuselage barrel;and the second replacement shear tie is attached to the second flange ofthe second stringer and the fourth flange of the fourth stringer suchthat the second splice plate and the second flange are interposedbetween the second replacement shear tie and the main section of thefuselage barrel and the second splice plate and the fourth flange areinterposed between the second replacement shear tie and the new sectionof the fuselage barrel.
 2. The fuselage barrel assembly according toclaim 1, wherein: the first butt joint and the second butt joint arecircumferentially spaced apart from each other; and the first butt jointand the second butt joint extend from a first end of the fuselage barrelto a second end of the fuselage barrel.
 3. The fuselage barrel assemblyaccording to claim 1, wherein the main section, new section, firstsplice plate, and second splice plate is made from a fiber-reinforcedpolymer.
 4. The fuselage barrel assembly according to claim 1, wherein:an entirety of the main section of the fuselage barrel iscircumferentially open; and an entirety of the new section of thefuselage barrel is circumferentially open.
 5. The fuselage barrelassembly according to claim 1, wherein an entire length of the newsection of the fuselage barrel is equal to an entire length of the mainsection of the fuselage barrel.
 6. The fuselage barrel assemblyaccording to claim 1, wherein the first splice plate and the secondsplice plate are made from the same material as the main section of thefuselage barrel and the new section of the fuselage barrel.
 7. Thefuselage barrel assembly according to claim 1, wherein the main sectionand the new section of the fuselage barrel each define less than a fullcircumference of the fuselage barrel; and the main section and the newsection of the fuselage barrel contact each other at the first buttjoint and the second butt joint such that no gap is between the mainsection and the new section of the fuselage barrel at the first buttjoint and the second butt joint.
 8. The fuselage barrel assemblyaccording to claim 1, wherein the main section of the fuselage barrelhas a seamless construction.
 9. The fuselage barrel assembly accordingto claim 8, wherein the new section of the fuselage barrel has aseamless construction.
 10. The fuselage barrel assembly according toclaim 1, wherein the fuselage barrel further comprises: a first fillerbetween the first splice plate and the first butt joint and between thefirst stringer and the third stringer; and a second filler between thesecond splice plate and the second butt joint and between the secondstringer and the fourth stringer.
 11. The fuselage barrel assemblyaccording to claim 10, wherein: the first splice plate is supported onand fastened to the first filler; and the second splice plate issupported on and fastened to the second filler.
 12. The fuselage barrelassembly according to claim 10, wherein the first filler and the secondfiller are made from a fiber-reinforced polymer.
 13. The fuselage barrelassembly according to claim 10, wherein: the first splice plate sitsflush against the first flange and the third flange; the second spliceplate sits flush against the second flange and the fourth flange; thefirst filler is interposed between the first flange and the thirdflange; and the second filler is interposed between the second flangeand the fourth flange.
 14. The fuselage barrel assembly according toclaim 1, wherein: the first butt joint and the second butt joint extendan entire length of the main section of the fuselage barrel and anentire length of the new section of the fuselage barrel; the firstsplice plate extends the entire length of the main section and the newsection of the fuselage barrel; and the second splice plate extends theentire length of the main section and the new section of the fuselagebarrel.
 15. The fuselage barrel assembly according to claim 14, furthercomprising a plurality of first replacement shear ties and a pluralityof second replacement shear ties, and wherein: the plurality of firstreplacement shear ties are coupled to and spaced apart along the firstsplice plate; and the plurality of second replacement shear ties arecoupled to and spaced apart along the second splice plate.
 16. Thefuselage barrel assembly according to claim 14, wherein: the firstsplice plate has a seamless construction; and the second splice platehas a seamless construction.
 17. The fuselage barrel assembly accordingto claim 14, wherein: the first splice plate comprises multiple firstsplice plate segments; and the second splice plate comprises multiplesecond splice plate segments.
 18. The fuselage barrel assembly accordingto claim 17, wherein: the first splice plate segments are interconnectedin an end-to-end manner longitudinally along the first butt joint; andthe second splice plate segments are interconnected in an end-to-endmanner longitudinally along the second butt joint.
 19. The fuselagebarrel assembly according to claim 17, further comprising: firstcouplers each fixed to and spanning at least portions of adjacent onesof the multiple first splice plate segments; and second couplers eachfixed to and spanning at least portions of adjacent ones of the multiplesecond splice plate segments.
 20. An aircraft, comprising: a pluralityof fuselage barrel assemblies interconnected to each other, wherein atleast one of the fuselage barrel assemblies comprises: a main section ofa fuselage barrel having a one-piece construction; a new section of thefuselage barrel having a one-piece construction and spliced to the mainsection along a first butt joint between the main section and the newsection and along a second butt joint between the main section and thenew section, wherein: the first butt joint and the second butt jointextend parallel to a longitudinal axis of the fuselage barrel; and themain section and the new section of the fuselage barrel each define lessthan a full circumference of the fuselage barrel; a first splice platefastened to the main section of the fuselage barrel and the new sectionover the first butt joint; a second splice plate fastened to the mainsection of the fuselage barrel and the new section over the second buttjoint; a first replacement shear tie coupled to the first splice plate;a second replacement shear tie coupled to the second splice plate; and aframe element coupled to both the first replacement shear tie and thesecond replacement shear tie; wherein: the plurality of fuselage barrelassemblies are interconnected in an end-to-end configuration at abuttingends of respective fuselage barrels of the fuselage barrel assemblies;the main section comprises a first stringer, extending parallel to thefirst butt joint, and a second stringer, extending parallel to thesecond butt joint; the new section comprises a third stringer, extendingparallel to the first butt joint, and a fourth stringer, extendingparallel to the second butt joint; the first stringer comprises a firstflange; the second stringer comprises a second flange; the thirdstringer comprises a third flange; the fourth stringer comprises afourth flange; the first splice plate is attached to the first flange ofthe first stringer and the third flange of the third stringer; thesecond splice plate is attached to the second flange of the secondstringer and the fourth flange of the fourth stringer; the firstreplacement shear tie is attached to the first flange of the firststringer and the third flange of the third stringer such that the firstsplice plate and the first flange are interposed between the firstreplacement shear tie and the main section of the fuselage barrel andthe first splice plate and the third flange are interposed between thefirst replacement shear tie and the new section of the fuselage barrel;and the second replacement shear tie is attached to the second flange ofthe second stringer and the fourth flange of the fourth stringer suchthat the second splice plate and the second flange are interposedbetween the second replacement shear tie and the main section of thefuselage barrel and the second splice plate and the fourth flange areinterposed between the second replacement shear tie and the new sectionof the fuselage barrel.